Method of producing chenille



y 1962 P. SARKISSIAN 3,032,457

METHOD OF PRODUCING CHENILLE Filed Oct. 31, 1955 2 Sheets-Sheet 1 D c Q N \I 1 I I I 0 &

PARKE V .SARK/SSMN INVENTOR.

P. SARKISSIAN May 1, 1962 METHOD OF PRODUCING CHENILLE 2 Sheets-Sheet 2 Filed Oct. 31, 1955 PA RKE V SARK/SS/A N IN V EN TOR.

United States Patent Calif., a corporation Filed Oct. 31, 1955, Ser. No. 543,788 3 Claims. (Cl. 156-178) The present invention relates to a method and apparatus for producing a yarn product comparable to chenille yarn, and the production of a woven rag rug product therefrom. The invention also includes a novel rug which is produced from the particular yarn of the invention. The invention is characterized in that it makes possible the production of a yarn which is comparable to woven chenille yarn in a very inexpensive and expeditious way, and without weaving.

Chenille yarn is of course commonly known in the textile industry. In is produced by a weaving process, and rugs are made from the chenille yarn by a weaving process. The production of rag rugs by the weaving of strips of material cut from textile fabrics is, of course, known to the prior art. Such rugs of course have a particular and readily recognizable texture, quality, finish, etc. In the present invention the initial yarn product is made by a process of chenilling strips of any textile fabric by making lateral cuts in the edges of the strip and fraying the lateral tabs thus formed and removing the remnant warp strands from between the tabs. The various lengths of strips so formed are then attached to form a continuous strip or yarn by means of attaching the strips together at their ends. In the preferred form of the invention this is done by cementing the strips to a continuous strand or fiber which may be sisal fiber for example. The resulting yarn is a product which is comparable to chenille yarn but is easierto produce and from the standpoint of materials is utilitarian in that it utilizes waste products of the textile industry. The yarn so formed is woven by known weaving processes into a rug which has texture and qualities considerably superior to and readily recognizable from ordinary rag rugs known to the prior art. The texture and quality of the ultimate product is comparable to that of chenille rugs.

-The process for producing the yarn product involves particular steps whereby the yarn is produced in continuous strands in a most efficient and expeditious manner, the yarn after being so produced being ready for weaving by means of known weaving apparatus. The invention provides a machine for carrying out the process and automatically producing the continuous strands of yarn in an expeditious manner from any woven textile material which is fed into the machine. The machine provides for cementing or otherwise attaching continuous filler fibers to the original textile material from which the yarn is to be made. The machine then automatically makes lateral cuts in the textile material adjacent the filler or carrier fibers, and the textile material is then cut into strips. By cutting the material longitudinally midway between the carrier fibers attached thereto the resulting strips are strips each of which is attached to a carrier fiber with lateral cuts in the edges of the strip so that it is chenilled. The carrier fibers form a filler and a means of attaching strips of various length together to form a continuous yarn.

In accordance with the foregoing an object of the invention is to produce an improved rug product having qualities comparable to a chenille rug, the rug being made from rags or waste products of the textile industry.

Another object of the invention is to provide a method of producing a yarn product comparable to a chenille yarn, by cutting the textile material into strips, chenilling ICC the edges of the strips, and attaching them together to form a continuous yarn.

Another object is to provide a yarn as in the previous object, wherein the strips are attached or cemented to a continuous carrier fiber which forms a filler and results in a continuous strand of yarn.

Another object is to provide a rug product woven from yarn produced in accordance with the foregoing objects.

Another object of the invention is to provide a machine for carrying out a process of producing a yarn product as set forth in the foregoing.

Another object of the invention is to provide a machine for producing a yarn product wherein a textile material is carried on a continuous moving belt and continuous strands of carrier or filler material are cemented to the textile material along spaced parallel lines, the machine having means for then making parallel transverse cuts in the textile material between the carrier fibers and then slitting the material lengthwise into strips, midway between the carrier fibers.

Another object of the invention is to provide a machine as in the foregoing object, wherein cement is applied to the carrier fibers by means of a roller over which the fiber passes, and the fibers are carried in engagement with the textile material for cementing them thereto by a group of continuous chain members having channels for guiding the carrier fibers and pressing them into engagement with the textile material.

Further objects and numerous advantages of the invention will become apparent from the following detailed description and annexed drawings, wherein:

FIG. 1 is a schematic view of a part of a machine or apparatus adapted for carrying out the process of the invention;

FIG. 2 is an enlarged detail view taken along line 2-2 of FIG. 1;

FIG. 3 is a detail view taken along line 33 of FIG. 1;

FIG. 4 is a continuation of the schematic view of the machine of FIG. 1;

FIG. 5 is a detail view taken along the line 5-5 of FIG. 6; and

FIG. 6 is a detail view taken along the line 6-6 of FIG. 4.

Referring now more particularly to FIGS. 1 and 4 of the drawings, these figures show in schematic form a machine embodying the principles of the invention and on which the process of the invention can be carried out. The showing in these figures is essentially schematic, illustrating the principle of the invention without showing various details which form a part thereof but which in themselves are not critical to the principle of the invention.

In FIG. 1 numeral 10 designates an elongated platform or table supported by uprights as shown at 11. At the ends of the table or platform 10 are rollers 13 and 14 mounted on shafts supported in suitable bearings and being power driven by preferably an electric motor not shown. (See FIG. 4.) Passing over the rollers 13 and 14 is a continuous endless conveyor belt 17 which may be made of canvas or other comparable material. The roller 13 is supported from suitable frame structure 18 at the end of the platform 10. The upper part of the conveyor belt 17 passes over the top of the table or platform 10 in contact therewith. It is adapted to carry and convey thereon pieces of woven textile material as shown at 20, of various lengths and of a width corresponding to the width of the platform 10.

In the process of making the yarn product as described in the foregoing, it is preferable first to attach the filler or carrier fibers to the textile material, the carrier or filler serving to attach the pieces of textile material together as described. The carrier or filler strands o'r.

fibers, which may be .hemp or sisal fiber or the like, are initially on spools as shown at 22 in FIGS. 1 and 4. These spools are on individual shafts mounted in a frame 23 above the platform '10 as shown, supported from no rights as shown at 24. These filler strands as described in the foregoing, are applied to the textile fabric along parallel lines and are cemented thereto as will be described. The apparatus for guiding and applying the strands to the textile fabric includes a group of sprocket wheels as shown at 26, mounted on a shaft which is driven by power means not shown, and another similar groupof sprocket wheels 27 mounted on a shaft. Passing over corresponding sprocket wheels 26 and 27 are a group of link roller chains 29 shown in greater detail in FIG. 2. The link chains are of a type such that the side links form a groove or channel therebetween adapted to carry the carrier or filler strand therein as shown at 30, and to guide the strand and carry it next to the fabric 20 and apply it thereto.

Before being applied to the fabric, cement is applied to one side of'the filler or carrier fiber so that the fibers are cemented to the textile material along parallel relatively closely spaced lines. The mechanism for applying cement to the carrier fiber and bringing it 'to the chains 29 for application to the textile material includes a frame structure 32 supported from the framework of the platform 10. Numeral 33 designates a framework supporting a tank 34 of adhesive or cement which flows down through a tube 35 and out of a nozzle 36 and into a pan 40. Numeral 41 designates an adjustable frame carried on a cross shaft 42 which has mounted thereon a pair of tangential rollers 44 and 45. The roller 45 'extends into the adhesive or cement in the pan 40 and it applies or transfers adhesive or cement in a thin film to the roller 44, these rollers being power driven by means not shown.

The individual filler strands or fibers pass down from the spools 22 over rollers 47 mounted on the framework 33. The strands then pass over a guide block 48 having individual guides 49 for each of the strands. The strands then pass under a tensioning roller 51, over a tensioning roller 52, and under another tensioning roller 53. The strands then pass over a roller 55 which tensions the link chains 29 and they pass in tangential engagement with the roller 44 which transfers adhesive or cement from the film thereon onto one side of the strands or fibers 30. The strands 30 then pass individually into the grooves or channels formed in the link chains 29 as shown, so that the fibers are at all times carefully guided and controlled and are under sufficient tension so that the cement is applied to only one side thereof, which is the downward side, as the fibers are carried around by the sprocket wheels 26 and are applied to the fabric 20 with the cemented side down, so as to be in contact with the fabric 20. As the link chains pass along in contact with the fabric 20 as it moves along with the conveyor 17, the strands 30 are held in contact with the fabric with an appropriate degree of pressure and along guided parallel lines, as provided by the link chains. As the strands 30 pass the link chain assembly they are cemented to the fabric 20 along parallel lines as explained.

The fabric with the fibers attached then passes under a guide bar 59 having grooves as shown at 60 in FIG. 3, there being a groove for each of the fibers, and the strands then pass under a roller 62 mounted at its ends as shown. Numeral 64 designates a group of reflectors suspended above the platform as shown, the reflectors having heating lamps therein for purposes of drying the adhesive or cement so as to permanently adhere the strands or fibers 30 to the material 20. After passing the heating assembly the fabric with the strands attaching thereto passes under another guide bar 65 and roller 66.

Referring to FIG. 4, the material passes off the 'continuou's-conveyor 17 and onto a platform or table 67.

4 This table has a plate 68 which lifts the fabric 20 from the conveyor and it passes under a guide roller 69 and between two rollers 70 and 71 mounted on the table 67.

The material continues to the next part of the machine which carries out the steps of automatically providing transverse cuts in the fabric 20 between the filler or carrier fibers. As explained in the foregoing, after 'thes'e transverse cuts are made the fabric is slit lengthwise midway between the filler strands.

Numeral 73 designates a continuationof the table or platform structure beyond the platform 67 and between these structures are suitably mounted an upper roller 74 and lower rollers 75 and 76 over which the fabric 20 with the strands 30 attached passes. The material passes over an upper roller 77 from which it feeds to the mechanism for making the transverse cuts between the fibers 30. This mechanism comprises a group of similarly mounted knife blades 80 as shown in detail in FIG. 6. These blades are attached to arms 81 pivoted on a shaft 82. The arms 81 can be reciprocated by a stem 84, the upper end of which is connected to a shaft 85 attached to all of the arms 81. The lower end of the stem 84 has a bearing 87 engaging an eccentric disc 88 which has a pulley thereon driven by an electric motor 90 through a belt 91. g h

The knife blades 80 cooperate with another blade 93 mounted below them as shown in FIG. 4 on a frame 94. The fabric 20 passes over a roller 96 onto the frame 94 and beneath a guide plate 99 and between the knives 80 and 93. It will be understood that the knives 80 are arranged to be midway between the strands 30 which are attached to the fabric 20'. The knives 80 are reciprocatecl at an appropriate speed to make relatively closely spaced cuts completely through the fabric 20 between the strands 30, as may be observed from FIG. 6. Beneath the arms 81 the fabric feeds onto a guide platform 101 and then between guide members 102 and 103 which are ahead of parallel rotary cutting knives or discs 104. These discs are mounted on a power driven shaft and are spaced apart so as to each be midway between the strands 30. As the fabric 20 passes to the right it is slit into strips of yarn by the cutter knives or discs 104 and it passes off to the right in the form of individual strips of yarn, each having a filler ca'rier or fiber longitudinally cemented thereto, each strip being chenilled in that it has parallel transverse cuts in the side edges thereof. The final produce is therefore a yarn product comparable to chenille yarn but one which is made without utilization of a Weaving process. The yarn is one which is made from waste textile fabric the pieces of which are attached together by the carrier or filler strand which forms a central warp for each strand of the final yarn product. The individual yarns are carried into individual containers or receptacles not shown in the drawings.

The yarn product which is produced in accordance with the foregoing, is then woven into a rug in accordance with known weaving methods and techniques utilizing a loom as already known in the art. The resulting rug woven from the yarn product made as described, as in the nature of and has the qualities of a chenille rug. While it is made from Waste products of the textile industry, it has superior qualities to rag rugs as ordinarily known in the art. The resulting rug pr duct has distinct and readily recognizable qualities insofar as its texture, quality and feel are concerned, and as pointed out, is comparable to known chenille rugs made from chenille yarn.

From the foregoing it will be understood by those skilled in the art that the invention resides in the process of making a yarn product which is adaptable for weaving into rugs comparable to chenille rugs. The invention also resides in the apparatus and machinery which has been disclosed for carrying out the process. The particular apparatus is of advantage and is efiicaciou's in carrying out the process in that it automatically puts together pieces of textile material of various lengths by attaching the carrier fibers thereto; it chenilles the fabric in an eflicient manner, particularly in that it does so before the fabric is cut into strips of yarn, and the machine then slits the fabric into individual chenilled strips with the filler or carrier fiber attached thereto. The invention also resides in the final product which is a rug woven by known methods from the yarn product of the invention.

It should be understood that the process is susceptible to some variations in the steps thereof such as may be made by those skilled in the art. The apparatus has been illustrated schematically to demonstrate the principles thereof. It is also susceptible to some variation within the ability of those skilled in the art, and various details thereof, such as the exact manner of drive of the moving parts, the mounting of the spools of fiber or cord, etc., are details which may be varied considerably. It is to be understood therefore, that the disclosure herein is intended to be illustrative and representative of the invention rather than limiting thereon and that the scope of the invention is to be in accordance with the claims appended hereto.

I claim:

1. A method of making a chenille yarn product comprising, adhering a continuous strand of filler to one side of a woven fabric, making transverse cuts in the fabric on each side of the filler to adjacent the filler, fraying the woven fabric between the transverse cuts on each side of the fabric, and removing the cut strands of fabric from both sides of the filler leaving uncut fabric on both sides of the filler.

2. The method of making a continuous yarn product which comprises placing strips of woven fabric in longitudinal end-to-end relationship, cementing a continuous strand of filler longitudinally over such strips of woven fabric, and fraying the edges of said woven fabric leaving a portion of the woven fabric adjacent the filler bonded to the filler.

3. The method of making a yarn product which comprises attaching a plurality of continuous strands of filler material in spaced apart parallel relation to pieces of woven fabric having their ends longitudinally in abutting relationship, making transverse cuts in the woven fabric between the strands of filler, slitting the Woven fabric longitudinally between the strands of filler, fraying the edges of the cut and slit woven fabric, and removing strands of woven fabric between the transverse cuts to define a continuous yarn comprising a filler material bonded and overlying a woven fabric with frayed edges.

References Cited in the file of this patent UNITED STATES PATENTS 1,970,365 Dudley et al. Aug. 14, 1934 1,981,741 Morton Nov. 20, 1934 2,290,386 Schindler July 21, 1942 2,456,923 Cogovan et a1. Dec. 21, 1948 2,508,128 Waards May 16, 1950 2,560,566 Graves et al July 17, 1951 2,697,227 Prupis et a1. Dec. 21, 1954 FOREIGN PATENTS 669,424 Great Britain 1952 691,254 Great Britain May 6, 1953 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No, 3,032,457 May 1, 1962 Parkev Sarkissian It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 1 line l9 for "In" read It column 4, llne 59 for "as", second occurrence, read is Signed and sealed this 18th day of September 1962.

(SEAL) Attest:

ERNEST w. SWIDER DAVID LADD Attesting Qfficer Commissioner of Patents 

2. THE METHOD OF MAKING A CONTINUOUS YARN PRODUCT WHICH COMPRISES PLACING STRIPS OF WOVEN FIBRIC IN LONGITIDINAL END-TO-END RELATIONSHIP, CEMENTING A CONTINUOUS STRAND OF FILLER LONGITUDINALLY OVER SUCH STRIPS OF WOVEN FIBRIC, AND FRAYING THE EDGES OF SAID WOVEN FIBRIC LEAVING A PORTION OF THE WOVEN FABRIC ADJACENT THE FILLER BONDED TO THE FILLER. 